EP1075933B1 - Mehrschichtiges Expansionsformteil aus Polypropylenharz, Verfahren zur Herstellung, und aus dem mehrschichtigen Expansionsformteil hergestellte Behälter und stossabsorbierendes Material für Fahrzeugunterteil - Google Patents

Mehrschichtiges Expansionsformteil aus Polypropylenharz, Verfahren zur Herstellung, und aus dem mehrschichtigen Expansionsformteil hergestellte Behälter und stossabsorbierendes Material für Fahrzeugunterteil Download PDF

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Publication number
EP1075933B1
EP1075933B1 EP00116199A EP00116199A EP1075933B1 EP 1075933 B1 EP1075933 B1 EP 1075933B1 EP 00116199 A EP00116199 A EP 00116199A EP 00116199 A EP00116199 A EP 00116199A EP 1075933 B1 EP1075933 B1 EP 1075933B1
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EP
European Patent Office
Prior art keywords
layer
polypropylene resin
molded article
resin layer
mfr
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Expired - Lifetime
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EP00116199A
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English (en)
French (fr)
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EP1075933A2 (de
EP1075933A3 (de
EP1075933B8 (de
Inventor
Naochika Kogure
Hiroyuki Gokuraku
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JSP Corp
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JSP Corp
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B27/065—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of foam
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
    • B29C44/02—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles
    • B29C44/04—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles consisting of at least two parts of chemically or physically different materials, e.g. having different densities
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/32—Layered products comprising a layer of synthetic resin comprising polyolefins
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/18—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by features of a layer of foamed material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/18—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by features of a layer of foamed material
    • B32B5/20—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by features of a layer of foamed material foamed in situ
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C49/00—Blow-moulding, i.e. blowing a preform or parison to a desired shape within a mould; Apparatus therefor
    • B29C49/42—Component parts, details or accessories; Auxiliary operations
    • B29C49/48—Moulds
    • B29C49/4802—Moulds with means for locally compressing part(s) of the parison in the main blowing cavity
    • B29C2049/4807—Moulds with means for locally compressing part(s) of the parison in the main blowing cavity by movable mould parts in the mould halves
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C49/00—Blow-moulding, i.e. blowing a preform or parison to a desired shape within a mould; Apparatus therefor
    • B29C49/02—Combined blow-moulding and manufacture of the preform or the parison
    • B29C49/04—Extrusion blow-moulding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C49/00—Blow-moulding, i.e. blowing a preform or parison to a desired shape within a mould; Apparatus therefor
    • B29C49/22—Blow-moulding, i.e. blowing a preform or parison to a desired shape within a mould; Apparatus therefor using multilayered preforms or parisons
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C49/00—Blow-moulding, i.e. blowing a preform or parison to a desired shape within a mould; Apparatus therefor
    • B29C49/42—Component parts, details or accessories; Auxiliary operations
    • B29C49/48—Moulds
    • B29C49/4802—Moulds with means for locally compressing part(s) of the parison in the main blowing cavity
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2023/00—Use of polyalkenes or derivatives thereof as moulding material
    • B29K2023/10—Polymers of propylene
    • B29K2023/12—PP, i.e. polypropylene
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/04—Condition, form or state of moulded material or of the material to be shaped cellular or porous
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/30—Vehicles, e.g. ships or aircraft, or body parts thereof
    • B29L2031/3044—Bumpers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2266/00—Composition of foam
    • B32B2266/02—Organic
    • B32B2266/0214—Materials belonging to B32B27/00
    • B32B2266/025—Polyolefin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/30—Properties of the layers or laminate having particular thermal properties
    • B32B2307/304—Insulating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
    • B32B2307/56—Damping, energy absorption
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2439/00—Containers; Receptacles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2605/00—Vehicles
    • B32B2605/08—Cars
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2607/00—Walls, panels
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/13—Hollow or container type article [e.g., tube, vase, etc.]
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/13—Hollow or container type article [e.g., tube, vase, etc.]
    • Y10T428/1352—Polymer or resin containing [i.e., natural or synthetic]
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/13—Hollow or container type article [e.g., tube, vase, etc.]
    • Y10T428/1352—Polymer or resin containing [i.e., natural or synthetic]
    • Y10T428/1376—Foam or porous material containing
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/13—Hollow or container type article [e.g., tube, vase, etc.]
    • Y10T428/1352—Polymer or resin containing [i.e., natural or synthetic]
    • Y10T428/1379—Contains vapor or gas barrier, polymer derived from vinyl chloride or vinylidene chloride, or polymer containing a vinyl alcohol unit

Definitions

  • the present invention relates to a multi-layer article molded of a multi-layer parison comprising a polypropylene resin layer on the surface of a foamed polypropylene resin layer, and is used as, for example, a light-weight heat insulating panel utilized for a floor, door or the like, a pallet, a container, an automotive member, or the like.
  • Multi-layer resinous molded articles in various forms in which a thermoplastic resin layer is formed on the surface of a foamed resin layer, have heretofore been known.
  • the problem of refuse has been causing great concern, and so there has been a demand for changing containers for fishery products made of an expansion-molded article of polystyrene resin particles, and the like, which have heretofore been disposable, to containers made of a multi-layer resinous expansion-molded article, in which a polypropylene resin layer is formed on the surface of a foamed polypropylene resin layer, to circulate them as returnable containers capable of sterilizing with steam.
  • Automotive members and the like have also been required to constitute with members made of the same multi-layer resinous expansion-molded article having a polypropylene resin layer on its surface as described above from the viewpoints of recycling ability, strength, lightweight property, heat insulating property and sound absorbing property.
  • this process has also involved a problem that when a polypropylene resin is used as a base resin, it is difficult to obtain a molded article having a low-density foamed resin layer the density of which is as low as at most 0.4 g/cm 3 , or when it is attempted to make the density of the foamed resin layer low, the resulting foamed resin layer tends to cause cell collapse and formation of open cells. As described above, this process has involved some problems to be solved.
  • US-A-5 628 453 describes an insulated cup, the body of said cup being formed from a sheet having three co-extruded plastic layers, whereby the inner layer and the outer layer are formed from a solid plastic material such as polypropylene and the intermediate layer is formed from a foamed plastic material such as polypropylene.
  • the present invention has been completed in view of the above-described problems involved in the prior art, and has as its object the provision of a multi-layer molded article of a polypropylene resin, which can be produced without need of such complicated processes that a molded article, which will become a resin layer on the surface of a foamed resin layer, is formed, and a foam is then poured thereinto, and is beautiful in appearance and excellent in lightweight property, mechanical strength, heat insulating property, cushioning property, chemical resistance, recycling ability, etc., a production process thereof and a container, automotive members produced thereby.
  • a multi-layer article molded of a multi-layer parison comprising a foamed polypropylene resin layer and an unfoamed polypropylene resin layer provided on the outer side of the foamed resin layer as defined in claim 1.
  • the molded article according to the present invention may preferably include a molded article in which the thickness of the propylene resin layer is 100 ⁇ m to 10 mm, and the overall density of the molded article is 20 to 400 kg/m 3 .
  • the area ratio of the fusion-bonded portion in the inner surface of the molded article may preferably be at least 25%, more preferably at least 60%, still more preferably at least 80%, particularly preferably at least 95%.
  • the molded article according to the present invention may further have a skin layer formed of a synthetic resin on the outer side of the resin layer.
  • the polypropylene resin used for the foamable molten resin may preferably have an MFR (F) of 0.3 to 20 g/10 min.
  • a container formed of the multi-layer molded article of the polypropylene resin described above wherein the overall density of the container is 30 to 400 kg/m 3 , and the thickness of the polypropylene resin layer is 200 ⁇ m to 5 mm.
  • a shock-absorbing material for automobile formed of the multi-layer molded article of the polypropylene resin described above, wherein the overall density of the shock- absorbing material is 25 to 300 kg/m 3 , and the thickness of the unfoamed polypropylene resin layer is 200 ⁇ m to 7 mm.
  • the member for automobile may be a member selected from among a bumper, pillar, instrument panel, spoiler, fender, side step, door trim, grille guard and trunk board.
  • a heat insulating panel composed of the multi-layer article of the polypropylene resin described above is provided.
  • the present invention will hereinafter be described with reference to the accompanying drawings.
  • Specific examples of the multi-layer molded article of the polypropylene resin (hereinafter may be referred to as the "molded article" simply) according to the present invention are illustrated in Figs. 1A and 1B.
  • the molded articles 1 according to the present invention have a structure that a polypropylene resin layer 13 is formed on the surface of a foamed polypropylene resin layer 12.
  • the molded article 1 according to the present invention is obtained by holding a multi-layer parison in a mold to compression-mold it.
  • the term "parison" as used in the present invention means a tubular or any other hollow plastic formed or molded article obtained by bonding the opposed ends of two sheets to each other, or extrusion, injection molding or the like and such that generally used in molding such as blow molding.
  • Figs. 2A and 2B illustrate examples of the multi-layer parison 6.
  • the molded articles 1 illustrate in Figs. 1A and 1B are obtained from the multi-layer parison illustrated in Fig. 2A and the multi-layer parison illustrated in Fig. 2B, respectively.
  • the multi-layer parison illustrated in Fig. 2A has a structure that a polypropylene resin layer 3 is laminated on the outer surface of a foamed polypropylene resin layer 2, and the multi-layer parison illustrated in Fig. 2B has a structure that a skin layer 4 is further laminated on the surface of the resin layer 3 of the multi-layer parison shown in Fig. 2A.
  • the resin layer 3 is preferably used a non-foamed body, a foamed body having a density of at least 0.4 g/cm 3 or a inorganic material-filled non-foamed body.
  • the multi-layer parison 6 can be obtained by uniting and laminating a foamable molten resin prepared by adding a foaming agent to a polypropylene resin forming a foamed resin layer 2, and melting and kneading the resultant mixture in an extruder, and a molten resin prepared by melting a polypropylene resin forming a resin layer 3 in another extruder (or in order to obtain a multi-layer parison further having a skin layer 4 on the face side of the resin layer 3, a molten resin prepared by melting a resin forming the skin layer 4 in a further extruder) in a die for co-extrusion, and co-extruding them through the die to a lower-pressure zone, thereby expanding the foamable molten resin
  • the polypropylene resin layer 13 (hereinafter may be referred to as "the resin layer 13 of the molded article” or simply “the resin layer 13”) in the molded article 1 according to the present invention corresponds to the resin layer 3 of the multi-layer parison 6.
  • the foamed polypropylene resin layer 12 (hereinafter may be referred to as “the foamed resin layer 12 of the molded article” or simply “the foamed resin layer 12") in the molded article 1 corresponds to the foamed resin layer 2 of the multi-layer parison 6.
  • the skin layer 4 in the multi-layer parison illustrated in Fig. 2B corresponds to the skin layer 14 (hereinafter may be referred to as "the skin layer 14 of the molded article” or simply “the skin layer 14") provided on the outer side of the resin layer 13 of the molded article 1 illustrated in Fig. 1B.
  • polypropylene resin used for forming the foamed resin layer 12 of the molded article i.e., the polypropylene resin used for forming the foamed resin layer 2 of the multi-layer parison 6, is used a polypropylene resin (hereinafter referred to as "Specific Polypropylene Resin A” simply) comprising a polypropylene resin as a main component, whose melt tension, MT (F) (cN) and melt flow rate, MFR (F) (g/10 min) satisfy the following relationship : log MT (F) > -0.74 log MFR (F) + 0.65
  • polypropylene resin which does not satisfy the relationship (1a) fails to form a formed resin layer 2 having a high expansion ratio and a great thickness.
  • Specific Polypropylene Resin A used for forming the foamed resin layer 2 is preferably such that the MT (F) (cN) and MFR (F) (g/10 min) satisfy the following relationship (5).
  • Such a polypropylene resin permits the formation of a foamed resin layer 2 having a higher expansion ratio and a greater thickness. log MT (F) > -0.74 log MFR (F) + 1.13
  • the MFR (F) of Specific Polypropylene Resin A is preferably 0.3 to 20 g/10 min. If MFR (F) is lower than 0.3 g/10 min, the foam extrusion temperature of a foamable molten resin obtained by melting and kneading such a Specific Polypropylene Resin A and a foaming agent must be made high. As a result, there is a possibility that the viscoelasticity of the resin may be lowered, so that the foaming agent may escape from the resin, resulting in a failure to form a foamed resin layer 2 of a closed cell structure.
  • a polypropylene resin (hereinafter referred to as "Specific Polypropylene Resin B" simply) comprising a polypropylene resin as a main component, whose melt tension, MT (U) (cN) and melt flow rate, MFR (U) (g/10 min) satisfy the following relationship (2a) when the MFR (U) is at least 0.3 (g/10 min) or whose MT (U) is at least 9,8 (cN) when the MFR (U) is not lower than 0.1 (g/10 min), but lower than 0.3 (g/10 min): log MT (U) > -1.02 log MFR (U) + 0.46
  • the resultant resin layer 3 can not follow the extension of the foamed resin layer 2 upon the molding of such a parison by a molding machine, so that uneven extension occurs in the resin layer 3 to cause a scale pattern, cracks and/or holes in the surface of the resin layer 3.
  • the resin layer 13 of the resulting molded article 1 also becomes insufficient.
  • any resin having an MFR (U) of lower than 0.1 (g/10 min) is low in flowability, the use of such a low-MFR resin makes it difficult to extrude the molten resin for forming the resin layer 3 unless the extrusion temperature in the die is made high.
  • the foamable molten resin for forming the foamed resin layer 2 requires to lower the foam extrusion temperature in the die until a viscosity suitable for expansion is achieved.
  • the resin having an MFR (U) of lower than 0.1 (g/10 min) is used as a resin for forming the resin layer 3, it is difficult to provide a good multi-layer parison by co-extruding it with the foamable molten resin for forming the foamed resin layer 2, and the heat of the molten resin for forming the resin layer 3 causes such problems that the cell structure of the foamed resin layer 2 is destroyed.
  • the MT (U) of Specific Polypropylene Resin B is at least 9,8 (cN)
  • the poor flowability of Specific Polypropylene Resin B can be offset by its strong tension upon melting so far as the MFR (U) is at least 0.1 (g/10 min).
  • a good expansion-molded article 1 can be provided without causing a scale pattern, cracks, holes and/or the like in the resin layer 13 of the molded article by taking the production conditions of the multi-layer parison, the molding conditions of the parison and the like into adequate consideration.
  • the MFR (U) of Specific Polypropylene Resin B is preferably at most 20 (g/10 min) for the purpose of preventing the drawdown of the resulting multi-layer parison 6.
  • the use of such a resin B provides a good molded article 1 having a resin layer 13 evener in thickness. log MT (U) > -1.02 log MFR (U) + 0.68 log MT (U) > -1.02 log MFR (U) + 0.89
  • the above-described specific resins A and B can be obtained in accordance with, for example, the following process. Namely, such a resin can be obtained by a process in which an ordinary polypropylene resin (the ordinary polypropylene resin used for obtaining Specific Polypropylene Resins A and B will hereinafter be referred to as "the raw polypropylene resin" in order to distinguish it from Specific Polypropylene Resins A and B) low in MT, a peroxide lower in 1-minute half-life temperature than the melting point of the raw polypropylene resin, and a main chain scission-preventing agent are poured into an aqueous medium to stir them, thereby impregnating the raw polypropylene resin with the peroxide and main chain scission-preventing agent such temperature and time conditions that the decomposition of the peroxide is prevented as much as possible, and at least a half of the whole peroxide remains, and the raw resin is then held for a prescribed period of time under temperature conditions that the 1-minute half-life temperature of the
  • the raw polypropylene resin may be used a propylene homopolymer or a copolymer of propylene with other monomers.
  • the other monomers include ethylene, 1-butene, isobutylene, 1-pentene, 3-methyl-1-butene, 1-hexene, 3,4-dimethyl-1-butene, 1-heptene and 3-methyl-1-hexene.
  • the copolymer may be either a random copolymer or a block copolymer.
  • a proportion of other monomer components in the copolymer be at most 5.0% by weight for the random copolymer or at most 20.0% by weight for the block copolymer in order that the properties inherent in the polypropylene resin are not impaired.
  • raw polypropylene resins as described above may be used either singly or in any combination thereof.
  • the raw polypropylene resin may be mixed other resin components such as ethylene resins such as high density polyethylene, low density polyethylene, linear low density polyethylene, linear very low density polyethylene, ethylene-butene copolymers and ethylene-maleic anhydride copolymers, ethylene-vinyl acetate copolymers, and styrene resins within limits not impeding the properties inherent in polypropylene as needed.
  • Examples of the peroxide used for preparing Specific Polypropylene Resins A and B from the raw polypropylene resin include lauroyl peroxide, m-toluoyl-benzoyl peroxide, benzoyl peroxide and bis(4-butylcyclohexyl) peroxydicarbonate.
  • a peroxide whose 1-minute half-life temperature is lower than the melting point of the raw polypropylene resin used is selected.
  • the main chain scission-preventing agent serves to prevent the main chain of the raw polypropylene resin being cut by the peroxide.
  • methyl methacrylate, divinylbenzene, triallyl cyanurate or the like is used.
  • As the aqueous medium is generally water to which a surfactant has been added.
  • Specific Polypropylene Resin A satisfying the relationship (1a) between MT (F) and MFR (F) can be obtained by controlling the length of branched chains and the proportion of branch points of the polypropylene resin having branched chains obtained in the above-described process.
  • the length of the branched chains is lengthened, and the proportion of the branch points is relatively lessened, thereby obtaining Specific Polypropylene Resin A satisfying the relationship (5).
  • Specific Polypropylene Resin B satisfying the relationship (2a) between MT (U) and MFR (U) can be prepared in the same manner as in the above-described Specific Polypropylene Resin A or may be obtained by improving its flowability with a lubricant or the like even in a polypropylene resin of a linear structure.
  • a polypropylene resin having branched chains is selected for preparation, thereby obtaining Specific Polypropylene Resin B satisfying the relationship (4a) or (6).
  • Specific Polypropylene Resins A and B are used for conveniently distinguishing the polypropylene resin used for forming the foamed resin layer 12 of the molded article and meeting the above-described specific requirements from the polypropylene resin used for forming the resin layer 13 of the molded article and meeting the above-described specific requirements. Accordingly, when a polypropylene resin meeting both requirements for the resin for forming the foamed resin layer 12 of the molded article and requirements for the resin for forming the resin layer 13 of the molded article is used, the foamed resin layer 12 and resin layer 13 of the molded article can also be formed with the same base resins.
  • the molded article according to the present invention after use, and scrap and burr occurred upon the production of the molded article are used as a recycle material by, for example, melting them, they may be recycled for use without limit so far as they satisfy the conditions for Specific Polypropylene Resins A and B.
  • Specific Polypropylene Resins A and B also include those in which other polymers than Specific Polypropylene Resins A and B are mixed as needed. However, it goes without saying that the resin obtained by mixing another polymer must satisfy the relationship between MT and MFR in Specific Polypropylene Resins A and B.
  • polymers capable of mixing with Specific Polypropylene Resins A and B may be used the same resins as those exemplified as other resin components capable of mixing with the raw polypropylene resin in the above-described processes as examples for obtaining Specific Polypropylene Resins A and B, and besides rubber such as ethylene-propylene rubber; polystyrene elastomers such as styrene-butadiene-styrene block copolymers, styrene-isoprene-styrene block copolymers and hydrogenated products thereof; and polyolefin elastomers comprising a polyolefin copolymer such as a propylene-ethylene block copolymer as a hard segment and polyolefin copolymer rubber such as an ethylene-propylene random copolymer or ethylene-propylene-diene random copolymer as a soft segment; and the like.
  • rubber such as ethylene-propylene rubber
  • the properties inherent in the polypropylene resin may possibly be impaired even when such a polymer satisfies the relationship between MT and MFR. Therefore, when other polymers are mixed with Specific Polypropylene Resin A or B, the mixture is prepared so as to contain the polypropylene component in a proportion of at least 65% by weight, preferably at least 80% by weight in the resin after the mixing.
  • Specific Polypropylene Resins A and B used in the present invention may be those prepared in such a manner that the MT and MFR of the resulting mixtures satisfy the respective relationships between MT and MFR by suitably mixing other polymers than the raw polypropylene resin with the raw polypropylene resin.
  • the melt tension (MT) in the present specification can be measured by means of a Melt Tension Tester II Model manufactured by Toyo Seiki Seisaku-Sho, Ltd. or the like, which has been produced in accordance with ASTM D 1238. Specifically, a melt tension tester equipped with a cylindrical orifice having a straight hole having a hole diameter of 2.09 mm and a length of 8 mm is used, a resin sample is extruded into a strand through the orifice under conditions of a resin temperature of 230°C and a piston speed of 10 mm/min to hang the strand on a pulley for detection of tension having a diameter of 45 mm, and the strand is taken up on a take-up roll having a diameter of 50 mm while gradually increasing take-up speed in a proportion of about 5 rpm/sec (take-up acceleration of strand:about 1.3 x 10 -2 m/sec 2 ).
  • the take-up speed is first increased until the strand hanged on the pulley for detection of tension is broken to determine a take-up speed R (rpm) at the time the strand has been broken.
  • the strand is then taken up at a fixed take-up speed of R x 0.7 (rpm) to measure a melt tension (MT) of the strand detected by a detector connected to the pulley for detection of tension with time and chart it taking MT (cN) on an axis of ordinate and time (second) on an axis of abscissa, thereby obtaining a graph having such amplitude as illustrated in Fig. 3.
  • the MT in the present invention means a median (X) of amplitude at a stable amplitude portion.
  • melt tension a value determined as described above from a graph obtained by take-up at a take-up speed of 500 (rpm) is regarded as a melt tension (MT). Incidentally, specific amplitude occurred rarely on the above graph is ignored.
  • melt flow rate MFR
  • examples of a resin or polymer (hereinafter referred to as resin simply) used for forming the skin layer 14 include thermoplastic resins, such as polyethylene resins such as low density polyethylene, high density polyethylene and linear low density polyethylene; polypropylene resins such as homopolypropylene, propylene-ethylene random copolymers, propylene-1-butene random copolymers, propylene-ethylene-1-butene random terpolymers, propylene-ethylene block copolymers and propylene-1-butene block copolymers; cyclic polyolefins; polycarbonate resins; polyester resins; polystyrene elastomers; polyolefin elastomers; and polyester elastomers.
  • thermoplastic resins such as polyethylene resins such as low density polyethylene, high density polyethylene and linear low density polyethylene
  • polypropylene resins such as homopolypropylene, propylene-ethylene random copolymers, propylene-1-buten
  • the skin layer 14 is not limited to a film or sheet, but may be in a fibrous form such as a nonwoven fabric or woven fabric.
  • the skin layer 14 is not limited to a single layer, but may be multi-layer.
  • additives such as infrared absorbers, infrared reflecting agents, flame retardants, flowability improvers, weathering stabilizers, colorants, heat stabilizers, antioxidants, nucleating agents, inorganic fillers and rubber may be suitably incorporated into the foamed resin layer 12, resin layer 13 and skin layer 14 of the molded article 1 as needed. It is particularly preferable that an inorganic material such as short fiber or clay be subjected to a surface treatment and added to the respective layers, thereby enhancing stiffness of the layers to provide a molded article 1 having high stiffness.
  • the thickness of the resin layer 13 of the molded article 1 according to the present invention is preferably 100 ⁇ m to 10 mm, more preferably 100 ⁇ m to 7 mm. If the thickness of the resin layer 13 is too small, the molded article 1 has a possibility that the surface smoothness thereof may be deteriorated to make the surface appearance thereof poor. If the thickness of the resin layer 13 is too great, the whole weight of the molded article 1 becomes heavy, so that it is hard to say that the molded article is light-weight according to the use of the molded article 1, and moreover the closed cell content in the foamed resin layer 12 of the molded article 1 may lower in some cases.
  • the quantity of heat of a molten resin forming the resin layer becomes high when the thickness of the resin layer is great, so that the foamed resin layer is heated by such heat, and the viscosity of the resin forming the foamed resin layer is lowered to fail to maintain cells, resulting in lowering of the closed cell content in the foamed resin layer.
  • a relatively high-density core layer can be caused to exist at a fusion-bonded portion of the opposed foamed resin layers in the inner surface of the multi-layer parison 6 by suitably selecting the molding conditions of the multi-layer parison 6 upon production of the molded article 1 from the parison 6.
  • Such a core layer functions like a rib and can be expected to have an effect of preventing the occurrence of shrinkage or deformation in the molded article 1.
  • the thickness of the core layer is preferably 0.1 to 5 mm, more preferably 0.1 to 3 mm, particularly preferably 0.1 to 1.5 mm. If the thickness of the core layer is too great, there is a possibility that the closed cell content in the foamed resin layer may be lowered to deteriorate the mechanical strength of the molded article 1.
  • the foamable molten resin for forming the foamed resin layer 2 of the multi-layer parison 6 is prepared by suitably melting and kneading Specific Polypropylene Resin A, a foaming agent and a cell stabilizer such as talc or the like in an extruder.
  • the molten resin for forming the polypropylene resin layer 3 is prepared by melting and kneading Specific Polypropylene Resin B and optionally various additives in an extruder.
  • the foamable molten resin and the molten resin are united and laminated in a ring die for co-extrusion and co-extruded to a lower-pressure zone, whereby the foamable molten resin can be expanded to obtain the multi-layer parison 6.
  • a multi-layer parison of a layer structure composed of 3 or more layers like the multi-layer parison illustrated in Fig. 2B used for obtaining an molded article 1 further having a skin layer 14 on the surface of the resin layer 13 of the molded article can be obtained by using the same number of extruders as the number of layers and a ring die for co-extrusion of a structure that a plurality of resins can be united and laminated according to the number of layers in the multi-layer parison.
  • foaming agent added to Specific Polypropylene Resin A for forming the foamed resin layer 12 of the molded article may be used either of a volatile foaming agent or a decomposable foaming agent. In order to obtain a foamed resin layer having a high expansion ratio, however, it is preferable to use a volatile foaming agent.
  • Examples of the volatile foaming agent include aliphatic hydrocarbons such as propane, n-butane, isobutane, n-pentane, isopentane, n-hexane, isohexane and cyclohexane; chlorinated hydrocarbons such as methyl chloride and ethyl chloride; and fluorinated hydrocarbons such as 1,1,1,2-tetrafluoroethane and 1,1-difluoroethane.
  • Examples of the decomposable foaming agent include azodicarbonamide.
  • the foaming agents mentioned above may be used in combination of two or more thereof.
  • a decomposable foaming agent also having a function as a cell stabilizer may be used in combination with a volatile foaming agent.
  • a foamable molten resin and molten resin(s) for forming a foamed resin layer, a resin layer 3 and a skin layer 4 provided as needed are respectively prepared in separate extruders (not illustrated), and these molten resins are extruded from the extruders to a lower-pressure zone while uniting and laminating them is a die 21, thereby obtaining a multi-layer parison 6.
  • An accumulator may be provided between the extruders and the die 21 or within the die 11 as needed.
  • a mold split in a male mold 22a and a female mold 22b is closed so as to hold the multi-layer parison 6 formed by the extrusion through the die 21 from its both sides.
  • the mold is closed, the multi-layer parison 6 is compressed on the inner surface of the mold to bring the multi-layer parison 6 into close contact with the inner surface of the mold while gradually deforming it into like a flat form.
  • an air vent (not illustrated) for discharging air in the interior of the parison is provided.
  • a molded article 1 obtained by bringing the opposed innermost foamed layers of the multi-layer parison 6 into complete contact with each other to integrate them without any space as illustrated in Figs. 1A and 1B is preferred because it is excellent in mechanical strength and dimensional stability.
  • the outer surface of the multi-layer parison 6 can be fully brought into close contact with the inner surface of the mold to obtain a molded article 1 conforming to the shape of the mold with good reproducibility and having good appearance.
  • a mold having a pattern in its inner surface is used, the transferability of the pattern to the resulting molded article becomes good, and so the appearance thereof is far excellent.
  • Figs. 4 and 5 conceptually illustrate an example of the production process of the molded article 1 according to the present invention, and the specific procedure for producing the molded article 1 according to the present invention is not limited to that illustrated.
  • a female mold 22b is constructed by a bottom part 24 and side parts 25 provided on 4 sides of the bottom part 24 in such a manner that the set-up and development of the female mold 22b can be conducted by moving the side parts 25. It is preferred that in the course of closing a male mold 22a and the female mold 22b, the molding be conducted while setting up the female mold 22b from a developed state.
  • a proportion of the fusion-bonded portion of the opposed foamed resin layers in the inner surface of the multi-layer parison 6 is expressed by an area ratio (%) of the fusion-bonded portion.
  • the area ratio of the fusion-bonded portion in the molded article 1 is preferably at least 25%, preferably at least 60%, more preferably at least 80%, particularly preferably at least 95% from the viewpoint of achieving sufficient mechanical strength and dimensional stability.
  • the area ratio of the fusion-bonded portion can be determined in the following manner.
  • the molded article 1 is cut at a plane perpendicular to the extrusion direction of the multi-layer parison 6 used for producing the molded article so as to divide it into 10 equal pieces.
  • the cut pieces of the molded article are then arranged in order that the molded article is made up, thereby determining a length (mm) of the fusion-bonded portion of the opposed foamed resin layers in the inner surface of the multi-layer parison at a right sectional surface in each cut piece of the molded article.
  • a value obtained by doubling this length is regarded as a length, L (mm) of the fusion-bonded portion.
  • a length, M (mm) of the inner circumferential edge of the void portion is determined.
  • the length, L of the fusion-bonded portion and the length, M of the inner circumferential edge of the void portion are determined as the respective totals of all the fusion-bonded portions and all the void portions in the sectional surface.
  • the area ratio naturally amounts to 100%.
  • the above-described measurement is conducted on all the right sectional surfaces (i.e., 9 sectional surfaces) in the respective cut pieces of the molded article, and an arithmetic mean of the area ratios of the fusion-bonded portion thus obtained is regarded as the area ratio (%) of the fusion-bonded portion in the molded article according to the present invention.
  • Specific Polypropylene Resin A and Specific Polypropylene Resin B are used as raw materials for forming the foamed resin layer 12 of the molded article and the resin layer 13 of the molded article, respectively.
  • the values of MT and MFR found from the foamed resin layer 12 and the resin layer 13 of the expansion-molded article may differ from the values of MT and MFR of the original Specific Polypropylene Resins A and B due to differences in heat history up to the provision of the molded article 1, and the like.
  • the values of MT and MFR found from the foamed resin layers 12 and the resin layers 13 of the resultant molded articles may differ from each other due to differences in extrusion conditions upon the production of the multi-layer parison, and the like.
  • the MT and MFR of the foamed resin layer 12 of the molded article are determined by using, as a sample for measurement, that obtained by placing a sample cut out of the foamed resin layer for about 15 minutes in a vacuum oven at 200°C to heat and melt it, thereby defoaming it.
  • the values of MT and MFR of the foamed resin layer 12 and the resin layer 13 determined from a sample cut out of the expansion-molded article are values determined in accordance with the same method as in the measurement of MT and MFR of Specific Polypropylene Resins A and B.
  • the melt tension, MT (F1) (cN) and the melt flow rate, MFR (F1) (g/10 min) obtained by measurement to the polypropylene resin forming the foamed resin layer 12 in the molded article satisfy the following relationship (1), and moreover the melt flow rate, MFR (U1) obtained by measurement to the polypropylene resin forming the resin layer 13 of the molded article is at least 0.3 (g/10 min), and the melt tension, MT (U1) (cN) and the melt flow rate, MFR (U1) (g/10 min) obtained by measurement to the polypropylene resin forming the resin layer 13 satisfy the following relationship (2), or the melt flow rate, MFR (U1) obtained by
  • melt tension, MT (F1) (cN) and the melt flow rate, MFR (F1) (g/10 min) obtained by measurement to the polypropylene resin forming the foamed resin layer 12 in the molded article satisfy the following relationship (3), and moreover the melt flow rate, MFR (U1) obtained by measurement to the polypropylene resin forming the resin layer 13 of the molded article is at least 0.5 (g/10 min), and the melt tension, MT (U1) (cN) and the melt flow rate, MFR (U1) (g/10 min) obtained by measurement to the polypropylene resin forming the resin layer 13 satisfy the following relationship (4), or it satisfies the relationship wherein the melt flow rate, MFR (U1) obtained by measurement to the polypropylene resin forming the resin layer 13 of the molded article is not lower than
  • the molded article according to the present invention is obtained by molding the multi-layer parison 6 having the resin layer 3 composed of a polypropylene resin on the outer surface of the foamed resin layer 2 composed of a polypropylene resin, the adhesion of the foamed resin layer 12 to the resin layer 13 in the molded article 1 according to the present invention is high.
  • MT and MFR of the polypropylene resins cut out of the foamed resin layer 12 and the resin layer 13 satisfy the respective relationships, the thickness of the resin layer 13 in the molded article 1 becomes uniform, the expansion ratio of the foamed resin layer 12 is sufficiently high, the thickness thereof is also sufficiently great, and the appearance of the molded article is excellent.
  • the density of the foamed resin layer 12 is preferably 20 to 500 kg/m 3 , more preferably 25 to 400 kg/m 3 . If the density of the foamed resin layer 12 exceeds 500 kg/m 3 , it is hard to say that the molded article is light-weight, and physical properties such as heat insulating property may possibly be deteriorated. If it is attempted to make the density of the foamed resin layer 12 lower than 20 kg/m 3 , the cell membrane making up the foamed resin layer 2 of the multi-layer parison becomes too thin, resulting in a possibility that molding may be difficult due to easy collapse of cells upon molding of the parison, and so the molded article 1 may not be provided as a good product.
  • the density of the foamed resin layer 12 in the molded article 1 is determined in accordance the following method. A portion of the foamed resin layer 12 is cut out of the expansion-molded article 1, the weight (g) of the sample cut out is divided by a volume (cm 3 ) found from the external size of the sample to convert the value found into a kg/m 3 unit.
  • the density of the foamed resin layer 12 may vary according to the place measured, samples are cut out of the foamed resin layer 12 of the molded article at 10 or more places in different portions such as a bottom and sides, and the density of each sample is measured, and the maximum and minimum values are excluded from the resultant measured values to take an arithmetic mean of the remaining values, thereby regarding the average value as the density of the foamed resin layer 12 of the molded article.
  • the thickness of the resin layer 13 of the molded article 1 according to the present invention is preferably 100 ⁇ m to 10 mm. If the thickness of the resin layer 13 is too small, the molded article 1 has a possibility that the surface smoothness thereof may be deteriorated to make the surface appearance thereof poor. If the thickness of the resin layer 13 is too great on the other hand, the whole weight of the molded article 1 becomes heavy, so that it is hard to say that the molded article is light-weight according to the use of the molded article 1.
  • the thickness of the resin layer 13 is determined by measurement of the section of the molded article 1. In this case, the measurement may also be conducted by enlarging the section through a microscope as needed, and using an enlarged projection drawing.
  • the thickness of portions of the resin layer 13 situated at the upper and lower, and right and left peripheries of the molded article 1 near mold clamps for the parison may exhibit a small value, and so it is preferred that the thickness of another main portion than those near the clamps should fall within the above range.
  • the overall density of the molded article 1 according to the present invention is generally 20 to 800 kg/m 3 , preferably 20 to 400 kg/m 3 . If the overall density of the expansion-molded article 1 exceeds 800 kg/m 3 , the lightweight property and heat insulating property of the molded article may possibly be deteriorated. If the overall density of the molded article 1 is lower than 20 kg/m 3 on the other hand, the mechanical properties such as compressive strength of the molded article may possibly be deteriorated.
  • the overall density of the expansion-molded article 1 is a value determined by dividing the weight (kg) of the expansion-molded article 1 by its volume (m 3 ) measured by sinking the molded article 1 in water.
  • the volume of such void portions is not subtracted from the value determined as the volume of the molded article.
  • Figs. 1A and 1B illustrate sectional shapes of specifically exemplified containers formed of the molded article 1 according to the present invention, in which the multi-layer parison is molded in such a manner that the opposed innermost foamed layers of the multi-layer parison are completely fusion-bonded to each other without any space, and a container space is defined.
  • those in which the overall density is 30 to 400 kg/m 3 are excellent in lightweight property and heat insulating property.
  • those in which the thickness of the resin layer 13 is 200 ⁇ m to 5 mm are excellent in high durability and surface smoothness, well balanced between appearance and lightweight property, undergo only minimal shrinkage after molding and have excellent mechanical strength against external force. Further, they can be sterilized with steam due to their excellent heat resistance and are hence particularly suitable for use as returnable containers.
  • Fig. 7 is a horizontal sectional view of an automotive bumper illustrated as a specific example of a shock-absorbing material for automobile formed of the molded article 1 according to the present invention.
  • the molded article 1 illustrated in Fig. 7 is obtained by compression-molding the multi-layer parison 6, and has a structure that the opposed inner-side foamed resin layers of the multi-layer parison 6 are fusion-bonded to each other at the central portion and both ends of the molded article 1 and not fusion-bonded to form void portions between the central portion and both ends.
  • the overall density thereof is controlled to 25 to 300 kg/m 3 , thereby providing a shock-absorbing material which is light-weight and excellent in energy- absorbing efficiency.
  • the thickness of the resin layer 13 is controlled to 200 to 7,000 ⁇ m, thereby providing a shock-absorbing material having excellent surface smoothness and impact resistance.
  • the volume of the shock-absorbing material formed of the molded article according to the present invention is preferably 5,000 to 400,000 cm 3 .
  • melt tensions, MT (cN) and melt flow rates, MFR (g/10 min) of polypropylene resins used in the following Examples and Comparative Examples are shown in Table 1.
  • Polypropylene resin MT (gf) MFR (g/10 min) Resin A SD632 (propylene resin); product of Montell Canada Co. 19.6 3
  • Resin C PM620A propylene-ethylene random copolymer
  • product of Nippon Polyolefin K.K. 0.4 8 Resin D J700GP homopolymer
  • Resin I Mixture of Resin B/Resin D 50/50 (weight ratio) 7.8 6
  • Resin A Into 100 parts by weight of Resin A, were incorporated 3 parts by weight of a master batch of cell stabilizer prepared by blending 5 parts by weight of sodium citrate and 10 parts by weight of talc into 100 parts by weight of a low density polyethylene resin. The resultant mixture was fed to an extruder having a bore diameter of 65 mm, and isobutane as a volatile foaming agent was forced in a proportion of 2 parts by weight per 100 parts by weight of Resin A into the resin in the extruder and kneaded to prepare a foamable molten resin.
  • a master batch of cell stabilizer prepared by blending 5 parts by weight of sodium citrate and 10 parts by weight of talc into 100 parts by weight of a low density polyethylene resin.
  • the resultant mixture was fed to an extruder having a bore diameter of 65 mm, and isobutane as a volatile foaming agent was forced in a proportion of 2 parts by weight per 100 parts by weight of Resin A into the resin in the extruder and
  • a colorant was mixed into Resin A, and the mixture was fed to an extruder having a bore diameter of 40 mm and heated and melted to prepare a non-foamable molten resin.
  • the foamable molten resin and the non-foamable molten resin were injected from the respective accumulators so as to cause them to join in a die, and to laminate a resin layer formed of the non-foamable molten resin on the outer surface of a foamed resin layer formed by expansion of the foamable molten resin, and extruded through the die to form a multi-layer parison with the resin layer laminated on the outer surface of the foamed resin layer.
  • a box-shaped split mold arranged right under the die was then closed so as to hold the multi-layer parison thus extruded as illustrated in Figs. 6A and 6B, thereby deforming the multi-layer parison into a flat form by the inner surface of the mold, and the pressure within the mold was reduced to bring the multi-layer parison into close contact with the inner surface of the mold, thereby molding it.
  • the resultant molded article was cooled and released from the mold to obtain a molded article in the form of a truncated cone-like container having an external size at an opening part of 300 mm x 260 mm, an external size at a bottom part of 260 mm x 180 mm, a height of 110 mm and a wall thickness of about 20 mm.
  • As the mold was used that subjected to a satinizing processing at its inner surface.
  • the molded article thus obtained had good surface profile, and a satin pattern on the inner surface of the mold finely appeared on the surface of the molded article. In addition, appearance failure caused by shrinkage deformation, buckling and/or the like was not observed.
  • the section of the molded article was observed.
  • the molded article was found to have a resin layer formed of the outer resin layer of the multi-layer parison on the surface of the foamed resin layer of the molded article, and the opposed inner surfaces of the foamed resin layer in the multi-layer parison were fully fusion-bonded to each other without any space.
  • the foamed resin layer was cut out of the molded article to measure the MFR (F1) and MT (F1) of the resin forming the foamed resin layer, thereby finding values of log MT (F1) and -0.74 log MFR (F) + 0.65.
  • the values are shown in Table 2.
  • the resin layer was cut out of the molded article to measure the MFR (U1) and MT (U1) of the resin forming the resin layer, thereby finding values of log MT (U1) and -1.02 log MFR (U1) + 0.46.
  • Table 3 The values are shown in Table 3.
  • Multi-layer parisons were separately obtained in the same manner as in Example 1 except that their corresponding resins for forming a foamed resin layer of a molded article shown in Table 2 and their corresponding resins for forming a resin layer of a molded article shown in Table 3 were respectively used.
  • Each of the parisons was molded to obtain a container-like molded article.
  • the molded articles thus obtained had good appearance like Example 1.
  • the opposed inner surfaces of the foamed resin layer in the multi-layer parison were fully fusion-bonded to each other without any space.
  • the various properties of the molded articles are shown in Tables 2 to 4.
  • Example 4 a mixed volatile foaming agent composed of 30% by weight of isobutane and 70% by weight of n-butane was used in place of isobutane used as the volatile foaming agent in Example 1.
  • a molded article was obtained in the same manner as in Example 1 except that a multi-layer parison obtained in the same manner as in Example 1 except that its corresponding resin for forming a foamed resin layer of a molded article shown in Table 2 and its corresponding resin for forming a resin layer of a molded article shown in Table 3 were used, and the amount of the volatile foaming agent was changed to 1.8 parts by weight per 100 parts by weight of Resin B and the expansion-molded article was molded by means of a box-shaped multipart mold different from the mold used in Example 1.
  • the molded articles thus obtained was not observed causing appearance failure by shrinkage deformation, buckling and/or the like, but had good appearance.
  • Example 7 the box-shaped multipart mold was used as a mold for molding the multi-layer parison to form a molded article in the form of a rectangular-parallelepiped container having an external size at an opening part of 300 mm x 230 mm, a height of 120 mm and a wall thickness of about 20 mm.
  • a multi-layer parison was formed in the same manner as in Example 1 except that the amount of the foaming agent was changed to 1.9 parts by weight.
  • a bumper-shaped mold arranged right under the die was then closed so as to hold the multi-layer parison thus extruded as illustrated in Figs. 4 and 5, thereby deforming the multi-layer parison into like a flat form by the inner surface of the mold, and the pressure within the mold was reduced to bring the multi-layer parison into close contact with the inner surface of the mold, thereby molding it.
  • the molded article thus obtained had good surface profile, and appearance failure caused by shrinkage deformation, buckling and/or the like was not observed. The section of the molded article was observed.
  • the molded article was found to have a resin layer formed of the outer resin layer of the multi-layer parison on the surface of the foamed resin layer of the molded article, and the area ratio of the fusion-bonded portion in the inner surface of the molded article was 66%.
  • the foamed resin layer was cut out of the molded article to measure the MFR (F1) and MT (F1) of the resin forming the foamed resin layer, thereby finding values of log MT (F1) and -0.74 log MFR (F1) + 0.65.
  • the values are shown in Table 2.
  • the resin layer was cut out of the molded article to measure the MFR (U1) and MT (U1) of the resin forming the resin layer, thereby finding values of log MT (U1) and -1.02 log MFR (U1) + 0.46.
  • Table 3 The values are shown in Table 3.
  • a multi-layer parison was obtained in the same manner as in Example 1 except that its corresponding resin for forming a foamed resin layer of a molded article shown in Table 2 and its corresponding resin for forming a resin layer of a molded article shown in Table 3 were used, and the parison thus obtained was molded in the same manner as in Example 1 to obtain a container-like molded article.
  • the molded article thus obtained was observed causing break at a part of the resin layer and partially exposing the foamed resin layer on the surface.
  • the various properties of the container-like molded article are shown in Tables 2 to 4.
  • the molded articles according to the present invention are such that the thickness and density of the foamed polypropylene resin layer making up a multi-layer molded article of a polypropylene resin can be optionally selected or controlled by adopting the above-described constitution, and so those having a foamed resin layer having a great thickness and a high expansion ratio may also be provided.
  • the molded articles according to the present invention are uniform in the thickness of the polypropylene resin layer making up the molded articles and good in appearance without causing a scale pattern, cracks, holes and/or the like in the surface of the resin layer.
  • the production process of a molded article according to the present invention comprises molding a multi-layer parison having a resin layer on the outer surface of a foamed resin layer in a mold in such a manner that at least part of the opposed innermost foamed layers of the multi-layer parison are fusion-bonded to each other. Therefore, complicated production processes and apparatus like the conventional process for obtaining a multi-layer molded article of a polypropylene resin of the structure that a foamed resin layer has a skin layer on its surface are unnecessary.
  • specific polypropylene resins are used as base resins, thereby improving the extension and drawdown tendency of the resin layer of the multi-layer parison and moreover improving the expansion and drawdown tendency of the foamed resin layer. Therefore, multi-layer molded articles of a polypropylene resin that have heretofore been difficult to obtain by the process of molding a multi-layer parison can be provided with good productivity.
  • the molded articles according to the present invention are excellent in lightweight property, heat resistance, chemical resistance, recycling ability, heat insulating property, cushioning property, damping property, mechanical strength such as compressive, tensile and bending strength.
  • the molded articles according to the present invention are also suitable for use as deep-draw molded articles and large-sized molded articles, and can be utilized as, to say nothing of returnable containers, light-weight heat insulating panels for floor, door or the like; structural members for automobile (particularly, shock-absorbing materials for automobile), such as pillars, bumpers, instrument panels, spoilers, fenders, side steps, door trims, grille guards and trunk boards; desks; chairs; floats; surfboards; pallets; etc.

Landscapes

  • Laminated Bodies (AREA)
  • Blow-Moulding Or Thermoforming Of Plastics Or The Like (AREA)
  • Extrusion Moulding Of Plastics Or The Like (AREA)
  • Molding Of Porous Articles (AREA)
  • Injection Moulding Of Plastics Or The Like (AREA)
  • Casting Or Compression Moulding Of Plastics Or The Like (AREA)

Claims (17)

  1. Mehrschichtiges Formteil aus einem mehrschichtigen Substrat, enthaltend eine geschäumte Polypropylenharzschicht und eine ungeschäumte Polypropylenharzschicht auf der Außenseite der geschäumten Harzschicht, wobei das Substrat verformt ist und wobei zumindest ein Teil der gegenüberliegenden Innenoberflächen der geschäumten Harzschicht im Substrat miteinander schmelzverbunden sind, wobei das die geschäumte Harzschicht des Formteiles bildende Polypropylenharz eine durch Messung des Formteiles erhaltene Schmelzespannung MT(F1) (cN) und eine Schmelzflussrate MFR(F1) (g/10 min) aufweist, die der folgenden Beziehung einer Gleichung log MT(F1) > -0,74 log MFR(F1) + 0,65 genügt und das die ungeschäumte Harzschicht des Formteiles bildende Polypropylenharz eine durch Messung des Formteiles erhaltene Schmelzespannung MT(U1) (cN) und eine Schmelzflussrate MFR(U1) (g/10 min) aufweist, die der folgenden Beziehung einer Gleichung log MT(U1) > -1,02 log MFR(U1) + 0,46    mit MFR(U1) ≥ 0,3
    oder einer Gleichung MT(U1) ≥ 9,8 (cN)    mit 0,2 ≤ MFR(U1) < 0,3
    genügt, wobei die Gesamtdicke des Formteiles 20 bis 400 kg/m3 beträgt.
  2. Mehrschichtiges Formteil nach Anspruch 1, wobei das die geschäumte Harzschicht des Formteiles bildende Polypropylenharz eine durch Messung des Formteiles erhaltene Schmelzespannung MT(F1)(cN) und eine Schmelzflussrate MFR(F1) (g/10 min) aufweist, die der folgenden Beziehung einer Gleichung log MT(F1) > -0,74 log MFR(F1) + 0,78 genügt und das die ungeschäumte Schicht des Formteiles ausbildende Polypropylenharz eine durch Messung des Formteiles erhaltene Schmelzespannung MT(U1) (cN) und eine Schmelzflussrate MFR(U1) (g/10 min) aufweist, die der folgenden Beziehung einer Gleichung log MT(U1) > -1,02 log MFR(U1) + 0,68    mit MFR(U1) ≥ 0,5
    oder einer Gleichung MT(U1) ≥ 9,8 (cN)    mit 0,2 ≤ MFR(U1) < 0,5
    genügt.
  3. Mehrschichtiges Teil nach Anspruch 1 oder 2, wobei die Dicke der auf die Oberfläche der geschäumten Polypropylenharzschicht aufgebrachten ungeschäumten Polypropylenharzschicht 100 µm bis 10 mm beträgt.
  4. Mehrschichtiges Teil nach Anspruch 1 oder 2, wobei das Flächenverhältnis des integral miteinander verbundenen Bereiches der gegenüberliegenden Innenoberflächen des zu dem Teil geformten mehrschichtigen Substrates mindestens 25 % beträgt.
  5. Mehrschichtiges Teil nach Anspruch 1 oder 2, wobei das Flächenverhältnis des integral miteinander verbundenen Bereiches der gegenüberliegenden Innenoberflächen des zu dem Teil geformten mehrschichtigen Substrates mindestens 60 % beträgt.
  6. Mehrschichtiges Teil nach Anspruch 1 oder 2, wobei das Flächenverhältnis des integral miteinander verbundenen Bereiches der gegenüberliegenden Innenoberflächen des zu dem Teil geformten mehrschichtigen Substrates mindestens 80 % beträgt.
  7. Mehrschichtiges Teil nach Anspruch 1 oder 2, wobei das Flächenverhältnis des integral miteinander verbundenen Bereiches der gegenüberliegenden Innenoberflächen des zu dem Teil geformten mehrschichtigen Substrates mindestens 95 % beträgt.
  8. Mehrschichtiges Teil nach Anspruch 1 oder 2, welches weiterhin eine aus einem synthetischen Harz gebildete Hautschicht auf der Außenseite der ungeschäumten Harzschicht aufweist.
  9. Verfahren zum Herstellen eines mehrschichtigen Teils aus einem Polypropylenharz durch Formen, welches Koextrusion eines schäumbaren geschmolzenen Harzes umfasst, das erhalten wurde durch Hinzufügen eines Schäummittels zu einem Polypropylenharz, dessen Schmelzespannung MT(F) (cN) und Schmelzflussrate MFR(F) (g/10 min) der folgenden Beziehung einer Gleichung log MT(F) > -0,74 log MFR(F) + 0,65 genügt und Schmelzen und Kneten der erhaltenen Mischung mit einem geschmolzenen Harz, welches durch Schmelzen und Kneten eines Polypropylenharzes erhalten wurde, dessen Schmelzflussrate MFR(U) (g/10 min) mindestens 0,3(g/10min) beträgt und dessen Schmelzespannung MT(U) (cN) und Schmelzflussrate MFR(U)(g/10min) der folgenden Beziehung einer Gleichung log MT(U) > -1,02 log MFR(U) + 0,46 genügt oder dessen Schmelzflussrate MFR(U) nicht niedriger als 0,1 (g/10 min) liegt, aber unterhalb von 0,3 (g/10 min) liegt und dessen Schmelzespannung MT(U) mindestens 9,8 (cN) beträgt,
    wodurch ein mehrschichtiges Extrudat gebildet wird, welches eine ungeschäumte Polypropylenharzschicht aufweist, die aus dem geschmolzenen Harz auf der Oberfläche einer geschäumten Harzschicht zusammengesetzt ist, welche durch Expansion des schäumbaren geschmolzenen Harzes erhalten wurde, und dann Deformieren des mehrschichtigen Extrudates in eine flache Form und Formen des mehrschichtigen Extrudates in eine Form in der Weise, dass mindestes ein Teil der gegenüberliegenden Innenoberflächen der geschäumten Polypropylenharzschicht im Extrudat miteinander schmelzverbunden werden, um das Formteil mit einer ungeschäumten Polypropylenharzschicht auf der Oberfläche der geschäumten Polypropylenharzschicht zu erhalten.
  10. Verfahren zum Herstellen eines mehrschichtigen Teils aus einem Polypropylenharz durch Formen, welches Koextrusion eines schäumbaren geschmolzenen Harzes umfasst, das erhalten wurde durch Hinzufügen eines Schäummittels zu einem Polypropylenharz, dessen Schmelzespannung MT(F) (cN) und Schmelzflussrate MFR(F) (g/10 min) der folgenden Beziehung einer Gleichung log MT(F) > -0,74 log MFR(F) + 1,13 genügt und Schmelzen und Kneten der erhaltenen Mischung mit einem geschmolzenen Harz, welches durch Schmelzen und Kneten eines Polypropylenharzes erhalten wurde, dessen Schmelzflussrate MFR(U) (g/10 min) mindestens 0,8 (g/10 min) beträgt und dessen Schmelzespannung MT(U) (cN) und Schmelzflussrate MFR(U) (g/10 min) der folgenden Beziehung einer Gleichung log MT(U) > -1,02 log MFR(U) + 0,46 genügt oder dessen Schmelzflussrate MFR(U) nicht niedriger als 0,2 (g/10 min) liegt, aber unterhalb von 0,8 (g/10 min) liegt und dessen Schmelzespannung MT(U) mindestens 9,8 (cN) beträgt,
    wodurch ein mehrschichtiges Extrudat gebildet wird, welches eine ungeschäumte Polypropylenharzschicht aufweist, die aus dem geschmolzenen Harz auf der Oberfläche einer geschäumten Harzschicht zusammengesetzt ist, welche durch Expansion des schäumbaren geschmolzenen Harzes erhalten wurde, und dann Deformieren des mehrschichtigen Extrudates in eine flache Form und Formen des mehrschichtigen Extrudates in eine Form in der Weise, dass mindestes ein Teil der gegenüberliegenden Innenoberflächen der geschäumten Polypropylenharzschicht im Extrudat miteinander schmelzverbunden werden, um das Formteil mit einer ungeschäumten Polypropylenharzschicht auf der Oberfläche der geschäumten Polypropylenharzschicht zu erhalten.
  11. Verfahren nach Anspruch 9 oder 10, wobei das für das schäumbare geschmolzene Harz verwendete Polypropylenharz einen MFR(F) von 0,3 bis 20 g/10 min aufweist.
  12. Verfahren nach Anspruch 9, 10 oder 11, wobei die geschäumte Polypropylenharzschicht eine Dichte von 25 bis 400 kg/m3 aufweist.
  13. Behälter, gebildet aus dem mehrschichtigen Teil aus Polypropylenharz nach Anspruch 1 oder 2, wobei die Gesamtdichte des Behälters 30 bis 400 kg/m3 beträgt und die Dicke der ungeschäumten Polypropylenharzschicht 200 µm bis 5 mm beträgt.
  14. Ein stoßabsorbierendes Material für Automobile, gebildet aus dem mehrschichtigen Teil aus Polypropylenharz nach Anspruch 1 oder 2, wobei die Gesamtdichte des stoßabsorbierenden Materials 25 bis 300 kg/m3 und die Dicke der ungeschäumten Polypropylenharzschicht 200 µm bis 7 mm beträgt.
  15. Bauteil für Automobile, gebildet aus dem mehrschichtigen Teil aus dem Polypropylenharz nach Anspruch 1 oder 2.
  16. Bauteil für Automobile nach Anspruch 15, wobei das Bauteil für Automobile ein Bauteil ist, welches aus einer Stoßstange, Säule, Instrumentenpaneel, Spoiler, Schmutzfänger, Trittbrett, Türverkleidung, Grillschutzgitter und Kofferraumplatte ausgewählt ist.
  17. Wärmeisolierende Paneele, zusammengesetzt aus dem mehrschichtigen Teil aus dem Polypropylenharz nach Anspruch 1 oder 2.
EP00116199A 1999-08-09 2000-08-03 Mehrschichtiges Expansionsformteil aus Polypropylenharz, Verfahren zur Herstellung, und aus dem mehrschichtigen Expansionsformteil hergestellte Behälter und stossabsorbierendes Material für Fahrzeugunterteil Expired - Lifetime EP1075933B8 (de)

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